Emulsion fuel from sonication-generated asphaltenes

ABSTRACT

An emulsification method for converting deasphalted oil and/or asphaltenes into more suitable products for market demands and utilization in self sufficient energy production treatments plants is disclosed. Asphaltenes and residues from sonication of heavy oil feedstocks, as well as de-asphalted oil, may be used in combination with water and other chemical additives for conversion into a suitable fuel which may be stored, handled, and transported.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119 to U.S. Provisional Patent Application Ser. No. 61/798,955, entitled “Emulsion Fuel from Sonication-generated Asphaltenes,” filed Mar. 15, 2013, the entire contents of which are hereby incorporated herein by reference.

BACKGROUND

1. Field of the Disclosure

The present disclosure relates generally to sonic treatment of heavy oil feedstocks, and more particularly, to a method for converting asphaltenes from sonication into an emulsion fuel.

2. Background Information

Refineries, power plants among others may not always be suited for processing and burning different types of heavy hydrocarbons. Viscosity, density, asphaltenes, heavy metals, sulfur and other impurities in those fuels demand processing to modify and/or upgrade their chemical properties. Low viscosity is required to make them suitable for transportation, storage and utilization. For those reasons, demand of lighter fuels has increased, but such demand entails higher prices and operational costs.

In order to use heavy hydrocarbons, such as asphaltenes, power plants, refineries and the like, use a variety of methods to make heavy hydrocarbons suitable for power, heat and steam generation. Current methods include heating, chemical addition of solvent and reducers, and blending with other type of fuels like diesel and kerosene amongst others. Such methods are expensive because they require high level of energy consumption and large volume of chemical additives. Furthermore, blending may reduce volume of other suitable fuels, decreasing sale revenues.

The increasing demand for petroleum products has moved the oil industry towards using heavy oil feedstock byproducts, as well as other type of heavy hydrocarbons, for powering their operations, but power plants and refineries continue to face processing problems and higher costs. In order to improve operational results from processing of heavy oil feedstocks, a method for recovery and economical utilization of asphaltenes may be necessary to address a plurality of problems encountered in current art.

SUMMARY

Present disclosure may provide an emulsification procedure to recover and convert asphaltenes and de-asphalted oil from heavy oil feedstocks into an emulsified fuel which may be more suitable for transportation, storage and utilization in a plurality of applications.

The emulsification procedure may be integrated with de-asphalting process for providing main component of emulsion, such component may be asphaltenes, de-asphalted oil (DAO), or a combination of both. Furthermore, de-asphalting process may include sonication to improve separation of asphaltenes and DAO from heavy oil feedstocks. Combining sonication in de-asphalting process with the emulsification procedure may provide suitable fuel that may be fed to generators and other plant equipment for producing power, steam and heat, thus making de-asphalting plant using sonic treatment self sufficient in regards to energy requirements. Additionally, the emulsion fuel that may be converted from asphaltene, DAO, or a combination of both may be made available for a plurality of industry applications.

Mixing asphaltenes, DAO, or both with other emulsion elements, such as water and chemical additives, may produce an emulsion fuel. A variety of emulsions may be produced by a plurality of emulsification methods. Such methods may include static or dynamic mixers, and recirculation layouts amongst others to convert asphaltenes, DAO, or a combination of both into an emulsion fuel.

The stability of the emulsion may depend on the efficiency of the emulsion method. If a higher stability may be desirable, then it may be necessary to employ a more efficient method, and mixing may require a specific mixer design to address the level of efficiency. In addition, by increasing mixing time, emulsion stability may be improved. Lower stability of emulsion may be related to a sooner utilization of emulsion, while higher stability may be related to a later use of the emulsion, such as exportation, long storage time, as well as other factors which are determined by the operators.

Emulsion may reduce viscosity and the level of sulfur and heavy metals in the asphaltenes, as well as other properties such as flash point and oiliness amongst others. Transportation and storage costs may be reduced because of resultant low viscosity of the emulsion. This may enable a less expensive operation with conventional equipment. In addition, emulsion may be used as light fuel by conventional generators, which may include turbines, boilers, furnaces, internal combustion engines and other plant equipment. Therefore, a self sufficient energy loop may be established for plant operations, including production of heat and steam.

In one embodiment, a method of converting asphaltenes into emulsion fuel comprises: combining a first batch of heavy oil feedstock with a solvent to form a mixture; performing sonication on the mixture using a sonic reactor to separate deasphalted oil from asphaltenes; determining a number of mixing cycles or a mixing time for the emulsion based on a predetermined stability of emulsion, wherein the stability of the emulsion increases with additional mixing cycles or longer mixing time; and forming emulsion by mixing a fluid and a chemical additive with the asphaltenes for the determined number of mixing cycles or the determined mixing time to enhance designated characteristics of the emulsion.

In another embodiment, a method of converting deasphalted oil into emulsion fuel comprises: combining a first batch of heavy oil feedstock with a solvent to form a mixture; performing sonication on the mixture using a sonic reactor to separate deasphalted oil from asphaltenes; determining a number of mixing cycles or a mixing time for the emulsion based on a predetermined stability of emulsion, wherein a stability of the emulsion increases with additional mixing cycles or longer mixing time; and forming emulsion by mixing a fluid and a chemical additive with the deasphalted oil for the determined number of mixing cycles or the determined mixing time to enhance designated characteristics of the emulsion.

In another embodiment, an emulsion generating system comprises: an in-line mixer configured to receive heavy oil feedstock and solvent and mix the heavy oil feedstock and solvent to form a mixture; a sonicator configured to receive the mixture from the in-line mixer and apply a low-frequency, high-amplitude, high-vibrational energy to the mixture to separate deasphalted oil from asphaltenes comprising the mixture; a first reservoir configured to store the asphaltenes received from the sonicator and output the asphaltenes when a first control valve is activated; a second reservoir configured to store water and output the water when a second control valve is activated; a third reservoir configured to store a chemical additive and output the chemical additive when a third control valve is activated; a mixer configured to mix the asphaltenes, the water, and the chemical additive to form emulsion; and a recirculation valve configured to control a mixing time or a number of mixing cycles for the emulsion, wherein a stability of the emulsion increases with additional mixing cycles or longer mixing time.

These and other advantages of the present disclosure may be evident to those skilled in the art, or may become evident upon reading the detailed description of this method, as shown in the accompanying process flow chart.

Additional features and advantages of an embodiment will be set forth in the description which follows, and in part will be apparent from the description. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the exemplary embodiments in the written description and claims hereof as well as the appended drawings.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting embodiments of the present disclosure are described by way of example with reference to the accompanying figures which are schematic and are not intended to be drawn to scale. Unless indicated as representing the background art, the figures represent aspects of the disclosure.

FIG. 1 depicts a process flowchart for emulsification procedure, which shows a variety of steps and factors that may be integrated and analyzed for a correct emulsification procedure.

FIG. 2 illustrates a process flow diagram of an exemplary system for emulsification procedure using static mixers.

FIG. 3 illustrates a process flow diagram of an exemplary system for emulsification procedure using a mixing vessel and a mixer.

FIG. 4A depicts an isometric view of sonic reactor which may be used for asphaltene separation process.

FIG. 4B depicts a front view of sonic reactor which may be used for asphaltene separation process.

FIG. 4C depicts a cross sectional view of sonic reactor which may be used for asphaltene separation process.

FIG. 4D depicts a rear view of sonic reactor which may be used for asphaltene separation process.

DETAILED DESCRIPTION

In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, which are not to scale or to proportion, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings and claims, are not meant to be limiting. Other embodiments may be used and/or other changes may be made without departing from the spirit or scope of present disclosure.

DEFINITIONS

As used herein, the following terms may have the following definitions:

“Heavy oil feedstocks” may refer to materials that contain heavy oil with a specific gravity of less than 16 API.

“Asphaltenes” may refer to materials present in heavy oils and bitumens, which precipitate in n-alkanes solvent.

“Emulsion” may refer to a homogenous substance produced from different substances with different viscosity, specific gravities and the like.

“Emulsion components” may refer to substances and materials concentrated in an emulsion.

“Emulsification” may refer to the process of mixing emulsion components in order to obtain an emulsion.

“Sonication” may refer to any device or system which produces vibrational energy sufficient to impact one or more desired end uses.

DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a process flowchart for emulsification procedure 100. Emulsification procedure 100 may be implemented for the optimal production of an emulsion fuel which may be used as suitable fuel for power generation, heat, and steam production, as well as an emulsion fuel for existing markets.

Emulsification procedure 100 may start with de-asphalting process 102 which may provide main emulsion components. De-asphalting process 102 may combine solvent addition and sonication process to achieve asphaltenes and de-asphalted oils (DAO) separation from heavy oil feedstocks. Separation of asphaltenes from heavy oil feedstocks may be improved by sonication applied by a proprietary sonic reactor. Sonication may increase reaction rate between solvents and heavy oil feedstock in process, allowing a faster separation of asphaltenes and DAO from heavy oil feedstocks.

The mixture of heavy oil feedstock-solvent may be subjected to sonication at low frequency, high amplitude, high vibrational energy. Sonication may enable recovery of deasphalted hydrocarbons containing solvent and asphaltenes, residues and solvents. The quantities and properties of the separated asphaltenes and residues may depend on the temperature and nature and quantities of the solvent selected to produce an optimal efficiency of the recovered deasphalted hydrocarbon liquids. The sonication process may significantly reduce processing time from about six hours up to more than ten hours to about 5 seconds up to two minutes depending on the solvent-feedstock mixture being processed and enabling either batch or continuous production modes. Asphaltenes, residue, solvent and DAO may be separated inside the chamber of at least one proprietary sonic reactor. The sonication process that may be applied by proprietary sonic reactor may result in an optimal mass transfer.

De-asphalting process 102 may be directed by market demands and plant requirements for power, heat, steam and the like. De-asphalting process 102 may also provide the volume of emulsion demanded by the market, and an economic evaluation may be performed to determine cost-benefits to assign production according to power needs and market demands. Combination of sonication in de-asphalting process 102 with emulsification procedure 100 may allow the use of asphaltenes as a suitable fuel when converted in the emulsion.

Additionally, in de-asphalting process 102, processing of separated asphaltenes and residues may include the utilization of a plurality of technologies that may lead to recover solvent from the solvent-saturated asphaltenes and residues.

After de-asphalting process 102, emulsification 104 may start. Emulsification 104 may include a plurality of mixing technologies which may be used in mixing of emulsion components 106. Such emulsification 104 methods may employ static mixing, recirculation mixing, mixing by convection, mixing by sparkling amongst others.

Emulsion may be produced using one or more proprietary formulations, which may be related with the desired characteristics of emulsion. During mixing of emulsion components 106, asphaltenes, DAO or combination of both may be added to chemicals additives and other fluids in the mixing technologies of in the processing plant. Added fluid may be water in a volume concentration capable of enhancing characteristics of emulsion as per requirements. Enhanced characteristics for the desired emulsion fuel may be low viscosity, low oiliness, low sulfur levels and the like.

Chemical additives may be intended to reduce heavy metals concentrations, modify flash point, reduce viscosity, reduce sulfur levels, enable the use of solid heavy hydrocarbons and the like. Chemical additives may be concentrated in a range from 0.1% to 2% in emulsion.

Heat may also be present during mixing of emulsion components. Heat may increase mixing rate between components. Furthermore, heat may allow the use of solid heavy hydrocarbons as emulsion component.

Emulsion fuel may possess a stability which may be directly related with the efficiency of the emulsification 104 method that may be determined according to the components from de-asphalting process 102. Furthermore, for setting the stability of emulsion, storage time may be determined by use of emulsion 108. If emulsion fuel may be utilized in the self sufficient power system in the plant, then a quick emulsification 104 method may be used to provide a low stability of the emulsion fuel. Subsequently, emulsification procedure 100 may end. Otherwise, if the emulsion fuel may be destined to exportation or may be stored during long periods of time, then emulsion fuel may require a higher stability which may be achieved by a more efficient emulsification 104 method or may require multiple stages of mixing during emulsification 104. Thus, an additional mixing 110 stage or time may be required. Subsequently emulsion may be sent to an emulsion storage 112 for subsequent use and emulsification procedure 100 may end.

Emulsion may reduce transportation and storage costs because of its low viscosity. Thus, power generation may be achieved by the use of any type of generator, including: turbines, internal combustion engines and the like. Similarly, heat and steam may be produced by any conventional equipment. This may enable a cheap operation.

FIG. 2 depicts emulsification system 200, which may include two static mixers 202, control valves 204, reservoirs of emulsion elements, such reservoirs may include reservoir 1206 for water storage, reservoir II 208 may include asphaltene as main component of the emulsion (others hydro carbons may be used as described in FIG. 1) and reservoir III 210 may include chemical additives. Furthermore, emulsification system 200 may include one pump 212, a reservoir 214 for power, heat and steam generation as well as a reservoir 216 for a further use of emulsion; such as exportation, storage during long periods of time and the like.

FIG. 3 depicts emulsification system 300, which may include one mixing vessel 302, more mixer 304, control valves 204, reservoirs of emulsion elements, such reservoirs may include reservoir 1206 for water storage, reservoir II 208 may include asphaltene as main component the emulsion (others hydro carbons may be used as described in FIG. 1) and reservoir III 210 may include chemical additives. Furthermore, emulsification system 300 may include one pump 212, a reservoir 214 for power, heat and steam generation as well as a reservoir 216 for a further use of emulsion; such as exportation, storage during long periods of time and the like.

FIG. 4A shows an isometric view 402 of a sonic reactor 400, which may be used for asphaltene separation. Additionally, FIG. 4B, FIG. 4C and FIG. 4D show respectively: front view 404, cross sectional view 406 and rear view 408 of sonic reactor 400. Sonic reactor 400 is shown having support structure 410, resonant bar 412, and a set of magnet configuration 414, resonant bar supports 416, and reaction chamber 418 on each end of resonant bar 412.

Sonic reactor 400 may use support structure 410 to hold resonant bar 412 in place using any suitable support as resonant bar supports 416. Suitable configurations for resonant bar supports 416 may include configurations including three or more rubber air cushions. Any suitable magnet configuration 414, activated by a control module (not shown), may cause resonant bar 412 to vibrate, sonicating to heavy oil feedstocks in one or more reaction chamber 418. Suitable configurations for magnet configuration 414 include configurations with at least 3 magnets and power suitable to cause resonant bar 412 to vibrate.

Heavy oil feedstocks in reaction chamber 418 may have previously been chemically altered to allow asphaltenes separation in reaction chamber 418, methods for preparing it for such including the addition of one or more solvents.

Examples

Example #1 is an exemplary case of an emulsification system 200. Emulsification system 200 may utilize two static mixers 202 for obtaining an emulsion from the mixture of asphaltenes, water and chemical additives. A pump 212 may be set for feeding and controlling flow of emulsion elements into static mixers 202. Furthermore, control valves 204 may increase control of flow rate flowing from each reservoir and every flow rate in different parts of emulsification system 200. If a higher stability of emulsion is required, then a recirculation valve 218 may allow the recirculation of emulsion into the static mixers 202 every requested time. Once the emulsion is finished, it may be stored in a reservoir 216 for a further exportation, storage during long periods of time and the like. However, if there is an immediate need for power, heat and steam generation, then emulsion may be stored in a reservoir 214 intended for that purpose or may feed generators, furnaces, boilers, and the like in a direct connection without reservoir 214. Emulsion may enable its use in conventional generators, such as turbines, internal combustion engines and the like.

Example #2 is an exemplary case of an emulsification system 300. Emulsification system 300 may utilize mixing vessel 302 and mixer 304 for obtaining an emulsion from the mixture of asphaltenes, water and chemical additives. Such mixer 304 may be integrated by a motor, turbine and any other suitable power source for impulsing a propeller, helix and the like. A pump 212 may be set for feeding and controlling flow of emulsion elements into mixing vessel 302. Furthermore, control valves 204 may increase control of flow rate flowing from each reservoir and every flow rate in different parts of emulsification system 300. If a higher stability of emulsion is required, then a recirculation valve 218 may allow the recirculation of emulsion into the mixing vessel 302 every requested time. In addition, mixer 304 may operate during more time in order to perform a higher emulsion stability. Once the emulsion is finished, it may be stored in a reservoir 216 for a further exportation, long time storage and the like. However, if there is an immediate need for power, heat and steam generation, then emulsion may be stored in a reservoir 214 for that purpose or may feed generators, furnaces, boilers, and the like in a direct connection without reservoir 214. Emulsion may enable its use in conventional generators, such as turbines, internal combustion engines and the like.

While various aspects of this method may be described in the present disclosure, other aspects and embodiments may be contemplated. The various aspects and embodiments disclosed here are for purpose of illustration, and are not intended to be limiting with the scope and spirit being indicated by the following claims.

The embodiments described above are intended to be exemplary. One skilled in the art recognizes that numerous alternative components and embodiments that may be substituted for the particular examples described herein and still fall within the scope of the invention. 

What is claimed is:
 1. A method of converting asphaltenes into emulsion fuel comprising: combining a first batch of heavy oil feedstock with a solvent to form a mixture; performing sonication on the mixture using a sonic reactor to separate deasphalted oil from asphaltenes; determining a number of mixing cycles or a mixing time for the emulsion based on a predetermined stability of emulsion, wherein the stability of the emulsion increases with additional mixing cycles or longer mixing time; and forming emulsion by mixing a fluid and a chemical additive with the asphaltenes for the determined number of mixing cycles or the determined mixing time to enhance designated characteristics of the emulsion.
 2. The method of claim 1, wherein sonication applies a low frequency, high-amplitude, high-vibrational energy to the mixture
 3. The method of claim 1, further comprising: recovering solvent from the deasphalted oil and the asphaltenes by separating the solvent from the deasphalted oil and the asphaltenes; and combining a second batch of heavy oil feedstock with the recovered solvent.
 4. The method of claim 1, wherein the fluid is water.
 5. The method of claim 1, wherein the designated characteristics may be one or more from the group consisting of viscosity, oiliness, sulfur levels, flash point, and heavy metal concentrations.
 6. The method of claim 1, wherein the chemical additive has a concentration in the range of 0.1% to 2% in emulsion.
 7. The method of claim 1, further comprising: applying heat while mixing the asphaltenes with the fluid and the chemical additive.
 8. The method of claim 1, wherein the emulsion further comprises deasphalted oil.
 9. The method of claim 1, wherein mixing the fluid and the chemical additive to the asphaltenes is performed by static mixing, recirculation mixing, mixing by convection, or mixing by sparkling.
 10. A method of converting deasphalted oil into emulsion fuel comprising: combining a first batch of heavy oil feedstock with a solvent to form a mixture; performing sonication on the mixture using a sonic reactor to separate deasphalted oil from asphaltenes; determining a number of mixing cycles or a mixing time for the emulsion based on a predetermined stability of emulsion, wherein a stability of the emulsion increases with additional mixing cycles or longer mixing time; and forming emulsion by mixing a fluid and a chemical additive with the deasphalted oil for the determined number of mixing cycles or the determined mixing time to enhance designated characteristics of the emulsion.
 11. The method of claim 10, wherein sonication applies a low frequency, high-amplitude, high-vibrational energy to the mixture
 12. The method of claim 10, further comprising: recovering solvent from the deasphalted oil and the asphaltenes by separating the solvent from the deasphalted oil and the asphaltenes; and combining a second batch of heavy oil feedstock with the recovered solvent.
 13. The method of claim 10, wherein the fluid is water.
 14. The method of claim 10, wherein the designated characteristics may be one or more from the group consisting of viscosity, oiliness, sulfur levels, flash point, and heavy metal concentrations.
 15. The method of claim 10, wherein the chemical additive has a concentration in the range of 0.1% to 2% in emulsion.
 16. The method of claim 10, further comprising: applying heat while mixing the asphaltenes with the fluid and the chemical additive.
 17. The method of claim 10, wherein the emulsion further comprises asphaltenes.
 18. The method of claim 10, wherein mixing the fluid and the chemical additive to the deasphalted oil is performed by static mixing, recirculation mixing, mixing by convection, or mixing by sparkling.
 19. An emulsion generating system comprising: an in-line mixer configured to receive heavy oil feedstock and solvent and mix the heavy oil feedstock and solvent to form a mixture; a sonicator configured to receive the mixture from the in-line mixer and apply a low-frequency, high-amplitude, high-vibrational energy to the mixture to separate deasphalted oil from asphaltenes comprising the mixture; a first reservoir configured to store the asphaltenes received from the sonicator and output the asphaltenes when a first control valve is activated; a second reservoir configured to store water and output the water when a second control valve is activated; a third reservoir configured to store a chemical additive and output the chemical additive when a third control valve is activated; a mixer configured to mix the asphaltenes, the water, and the chemical additive to form emulsion; and a recirculation valve configured to control a mixing time or a number of mixing cycles for the emulsion, wherein a stability of the emulsion increases with additional mixing cycles or longer mixing time.
 20. The emulsion generation system of claim 19, wherein the first reservoir also stores deasphalted oil. 